Instruction Sheet CrimpingDieAssemblies 408--2786 220189-[]and58330-1 03 MAY 11 RevJ PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awide selection ofpowered application equipmentforextended--use,production operationsisavailable. Die Retaining Screws Stationary Jaw Indenter Die PRO--CRIMPER* III Frame Assembly Crimping Die 354940--1 (Ref) Assembly (Ref) Moveable Anvil Die Jaw Center Contact Ferrule Crimping Crimping Chamber Chamber DIEASSEMBLYPARTNUMBER CONNECTORBASEPARTNUMBER 220189--1, 220189--2 227000, 227079, 228980, 228979 220189--3 225395, 225396, 225397, 225398 58330--1 227079 Figure 1 Reasons for reissue are provided in Section 8, 1. INTRODUCTION REVISION SUMMARY. All dimensions in this document are in millimeters NOTE This instruction sheet covers the use and [with inches in brackets]. Figures and Illustrations maintenance of Crimping Die Assemblies listed in are for reference only and are not drawn to scale. i Figure 1. The dies are used in PRO--CRIMPER III Frame Assembly 354940--1 to crimp 50-- and 2. DESCRIPTION 75--Ohm BNC, and 50--Ohm TNC Dual--Crimp Connectors onto various size cable. Refer to Figure 1 Each die assembly consists of an indenter die and an for a list of connectors that are compatible with the anvil die, which when mated form two crimping die assemblies. Refer to Catalog 82074 for additional chambers. The large crimping chamber crimps the product part number information. For part numbers connector ferrule and the small crimping chamber not listed, contact TE Connectivity Product crimps the connector center contact. Each die is held Engineering for recommendations. in the tool by a single screw. See Figure 1. E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change. 1 of 5 All Rights Reserved PRODUCT INFORMATION 1--800--522--6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOCB TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-2786 3. DIEINSTALLATION Crimping the Center Contact To be sure that the die assembly is properly aligned during installation, proceed as follows: 1. Slide the die assembly into the partially--opened tool jaws. The anvil die must be installed in the movable jaw of the tool and the indenter in the stationary jaw. The center contact crimping chamber must be toward the front of the tool as Center Contact shown in Figure 1. Flange Butt Against Edge 2. Insert, but do not completely tighten, the die of Die retaining screws. 3. Close the tool jaws and carefully align the dies Anvil Die so that the anvil die enters the indenter die. Once the anvil has entered the indenter, place a copper bus bar (1.57+0.05 mm [.062+.002 in.] diameter) into the center contact crimping chamber of the die Stripped Cable assembly. 4. With bus bar in place, close the tool jaws Flange on End of completely. Hold the tool handles together and Cross--Sectional Center Contact tighten the die retaining screws with the View appropriate screwdriver. Edge of Die 4. CRIMPINGPROCEDURE Figure 2 For detailed information on cable selection, cable NOTE strip lengths, and proper assembly of the 4.2. Ferrule (Figure 3) connector, refer to the instructions provided with i the connector. 1. Insert the crimped center contact into the connector body until the cable dielectric butts Select the appropriate die assembly that is against the dielectric inside the connector body. compatible with the connector being used. Proceed The flared braid must fit around the support sleeve as follows: of the connector body. 4.1. CenterContact (Figure 2) Shoulder on 1. Slide the ferrule onto the cable, then strip the Connector cable to the proper dimensions. Body Butts Against 2. Slide center contact onto center conductor of Edge of Die cable; then insert contact assembly into the center contact crimping chamber of the anvil die. See Figure 2. Make sure that the flange on the end of the NOTE center contact butts against the edge of the die. Ferrule in Refer to the cross--sectional view in Figure 2. i Crimping Chamber on Anvil 3. Crimp the center contact by holding the cable in Die place; then close the tool handles until the ratchet releases. 4. Remove the crimped center contact assembly Figure 3 from the crimping dies. 2 of 5 RevJ 408-2786 2. Slide the ferrule forward over the braid until the 4. When the dies are not in use, mate and store ferrule butts against the shoulder on the connector them in a clean, dry area. body. 6.2. PeriodicInspections 3. Place the ferrule in the ferrule crimping chamber Regular inspections should be performed by quality of the anvil die so that the shoulder on the control personnel. A record of scheduled inspections connector body butts against the edge of the die. should remain with the dies and/or be supplied to SeeFigure3. supervisory personnel responsible for the dies. 4. Holding the assembly in place, close the tool Though recommendations call for at least one handles until the ratchet releases. inspection per month, the inspection frequency should be based on amount of use, working conditions, 5. Remove crimped assembly from the crimping operator training and skill, and established company dies. standards. These inspections should be performed in the following sequence: 5. CRIMPHEIGHTADJUSTMENT (Figure 4) Screwdriver The tool frame assembly ratchet mechanism features an adjustment wheel with numbered settings. If the crimp height is not acceptable, adjust the ratchet as follows: 1. Remove the lockscrew from the ratchet adjustment wheel. 2. With a screwdriver, adjust the ratchet wheel Ratchet from the opposite side of the tool. Adjustment Wheel 3. Observe the ratchet adjustment wheel. If a tighter crimp is required, rotate the adjustment wheel COUNTERCLOCKWISE to a higher--numbered setting. If a looser crimp is Lockscrew (Typ) required, rotate the adjustment wheel CLOCKWISE to a lower--numbered setting. Figure 4 4. Replace the lockscrew. A. VisualInspection 5. Make a sample crimp and measure the crimp height. If the crimp height is acceptable, secure the 1. Remove all lubrication and accumulated film by lockscrew. If the dimension is unacceptable, immersing the dies in a suitable commercial remove lockscrew and continue to adjust the degreaser. ratchet, and again measure a sample crimp. 2. Make certain all die retaining screws and die components are in place and secured. If replacements are necessary, refer to Section 7, 6. MAINTENANCEANDINSPECTION REPLACEMENT. 6.1. DailyMaintenance 3. Inspect the crimp area for flattened, chipped, worn, cracked, or broken areas. If damage is It is recommended that each operator of the tool with evident, the dies must be replaced (see Section 7, the die assembly be made aware of, and responsible REPLACEMENT). for, the following four steps of daily maintenance: 1. Remove dust, moisture, and other contaminants B. GagingtheCrimpingChamber with a clean, soft brush, or a clean, soft, lint--free This inspection requires the use of a plug gage cloth. Do NOT use any objects that could damage conforming to the diameters provided in Figure 5. TE the dies or tool. does not manufacture, or market, these gages. 2. Make sure that the proper die retaining screws Proceed as follows: are in place and secured. 1. Mate the dies until it is evident that they have 3. Make certain that all surfaces are protected with bottomed. Hold the dies in this position by holding a THIN coat of any good SAE 20 motor oil. the tool handles closed with moderate pressure. RevJ 3 of 5 408-2786 2. Align the GO element of the gage with the 7. REPLACEMENT crimping chamber. Push the element straight into Parts listed in Figure 6 are customer--replaceable. A the chamber without using force. The GO element complete inventory can be stocked and controlled to must pass completely through the crimping prevent lost time when replacement of parts is neces- chamber as shown in Figure 5. sary. Order replacements through your local TE Representative, or call 1--800--526--5142, or send a 3. Align the NO--GO element with the crimping facsimile of your purchase order to 1--717--986--7605, chamber and try to insert it straight into the or write to: chamber. The NO--GO element may start entry but must not pass completely through. See Figure 5. CUSTOMER SERVICE (38--35) TYCO ELECTRONICS CORPORATION P.O. BOX 3608 If the crimping chambers conform to the gage HARRISBURG, PA 17105--3608 inspection, the dies are considered dimensionally correct and should be lubricated with a thin coat of any good SAE 20 motor oil. If not, the dies must be replaced before returning them to service. 8. REVISIONSUMMARY S Updated document to corporate requirements. For additional information concerning the use of the plug gage, refer to Instruction Sheet 408--7424. Suggested Plug GageDesign for Suggested Plug GageDesign W GO CenterContactCrimping Chamber NO--GO GO forFerruleCrimping Chamber Dia Dia Dia NO--GO Dia R Crimping “GO” element must Chamber pass completely through the die closure. “NO--GO” element may enter partially, but must not pass completely through the die closure. GO Element NO--GO Element GAGEELEMENTDIAMETER(mm[in.]) CRIMPING CHAMBER D DIIE EA AS SS SE EM MB BL LY Y CENTERCONTACT FERRULE PARTNO. RADIUS WIDTH GO NO--GO GO NO--GO ‘‘R”(Max) ‘‘W”(Max) 1.207--1.214 1.359--1.367 5.156--5.164 5.408--5.410 2.51 5.03 220189--1 [.0475--.0478] [.0535--.0538] [.2030--.2033] [.2129--.2130] [.099] [.198] 1.054--1.062 1.181--1.189 5.969--5.977 6.220--6.223 2.92 5.84 220189--2 [.0415--.0418] [.0465--.0468] [.2350--.2353 [.2449--.2450] [.115] [.230] 1.925--1.928 1.984--1.986 5.405--5.408 5.667--5.669 2.64 5.28 220189--3 [.0758--.0759] [.0781--.0782] [.2128--.2129] [.2231--.2232] [.104] [.208] 1.029--1.036 1.181--1.189 4.191--4.199 4.442--4.445 2.03 4.06 58330--1 [.0405--.0408] [.0465--.0468] [.1650--.1653] [.1749--.1750] [.080] [.160] Figure 5 4 of 5 RevJ 408-2786 30.48 mm 11.89 mm [1.20 in.] [.468 in.] 2 34.80 mm [1.37 in.] 1 WEIGHT: 227g[8oz] CUSTOMER--REPLACEABLEPARTS DIEASSEMBLY ANVIL INDENTER PARTNO. (Item1) (Item2) 220189--1 310498--2 310497--2 220189--2 310498--4 310497--4 220189--3 310567--1 310568--1 58330--1 313764--1 313763--1 Figure 6 RevJ 5 of 5